Controllable coupling assembly and coupling member for use in the assembly

ABSTRACT

A controllable coupling assembly and a coupling member for use in the assembly are provided. The member includes a first coupling face oriented to face axially along a rotational axis and has a set of locking formations angularly-spaced about the axis. The member also includes a second coupling face having a reverse pocket which receives a reverse locking element. The pocket defines a first load-bearing surface adapted for abutting engagement with a load-bearing surface of the reverse locking element. The second coupling face is oriented to face radially with respect to the axis. Each of the set of locking formations defines a second load-bearing surface adapted for abutting engagement with a load-bearing surface of a forward locking element.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. application Ser. Nos.14/675,850 and 14/675,853 both filed Apr. 1, 2015. Those applicationsare continuation-in-part of U.S. application Ser. No. 14/288,819 filedMay 28, 2014, now U.S. Pat. No. 9,234,552, which claims benefit of U.S.provisional application Ser. No. 61/941,741 filed Feb. 19, 2014. Thisapplication is also related to U.S. application Ser. Nos. 15/078,154 and15/078,171, filed on the same date as this application.

TECHNICAL FIELD

This invention generally relates to controllable coupling assemblies andcoupling members for use in such assemblies.

OVERVIEW

Coupling assemblies such as clutches are used in a wide variety ofapplications to selectively couple power from a first rotatable drivingmember, such as a driving disk or plate, to a second, independentlyrotatable driven member, such as a driven disk or plate. In one knownvariety of clutches, commonly referred to as “one-way” or “overrunning”clutches, the clutch engages to mechanically couple the driving memberto the driven member only when the driving member rotates in a firstdirection relative to the driven member. Further, the clutch otherwisepermits the driving member to freely rotate in the second directionrelative to the driven member. Such “freewheeling” of the driving memberin the second direction relative to the driven member is also known asthe “overrunning” condition.

One type of one-way clutch includes coaxial driving and driven plateshaving generally planar clutch faces in closely spaced, juxtaposedrelationship. A plurality of recesses or pockets is formed in the faceof the driving plate at angularly spaced locations about the axis, and astrut or pawl is disposed in each of the pockets. Multiple recesses ornotches are formed in the face of the driven plate and are engageablewith one or more of the struts when the driving plate is rotating in afirst direction. When the driving plate rotates in a second directionopposite the first direction, the struts disengage the notches, therebyallowing freewheeling motion of the driving plate with respect to thedriven plate.

When the driving plate reverses direction from the second direction tothe first direction, the driving plate typically rotates relative to thedriven plate until the clutch engages. As the amount of relativerotation increases, the potential for an engagement noise alsoincreases.

Controllable or selectable one-way clutches (i.e., OWCs) are a departurefrom traditional one-way clutch designs. Selectable OWCs add a secondset of locking members in combination with a slide plate. The additionalset of locking members plus the slide plate adds multiple functions tothe OWC. Depending on the needs of the design, controllable OWCs arecapable of producing a mechanical connection between rotating orstationary shafts in one or both directions. Also, depending on thedesign, OWCs are capable of overrunning in one or both directions. Acontrollable OWC contains an externally controlled selection or controlmechanism. Movement of this selection mechanism can be between two ormore positions which correspond to different operating modes.

U.S. Pat. No. 5,927,455 discloses a bi-directional overrunning pawl-typeclutch, U.S. Pat. No. 6,244,965 discloses a planar overrunning coupling,and U.S. Pat. No. 6,290,044 discloses a selectable one-way clutchassembly for use in an automatic transmission. U.S. Pat. Nos. 7,258,214and 7,344,010 disclose overrunning coupling assemblies, and U.S. Pat.No. 7,484,605 discloses an overrunning radial coupling assembly orclutch.

A properly designed controllable OWC can have near-zero parasitic lossesin the “off” state. It can also be activated by electro-mechanics anddoes not have either the complexity or parasitic losses of a hydraulicpump and valves.

In a powershift transmission, tip-in clunk is one of most difficultchallenges due to absence of a torque converter. When the drivertips-in, i.e., depresses the accelerator pedal following a coastcondition, gear shift harshness and noise, called clunk, are heard andfelt in the passenger compartment due to the mechanical linkage, withouta fluid coupling, between the engine and powershift transmission input.Tip-in clunk is especially acute in a parking-lot maneuver, in which avehicle coasting at low speed is then accelerated in order to maneuverinto a parking space.

In order to achieve good shift quality and to eliminate tip-in clunk, apowershift transmission should employ a control strategy that isdifferent from that of a conventional automatic transmission. Thecontrol system should address the unique operating characteristics of apowershift transmission and include remedial steps to avoid theobjectionable harshness yet not interfere with driver expectations andperformance requirements of the powershift transmission. There is a needto eliminate shift harshness and noise associated with tip-in clunk in apowershift transmission.

For purposes of this disclosure, the term “coupling” should beinterpreted to include clutches or brakes wherein one of the plates isdrivably connected to a torque delivery element of a transmission andthe other plate is drivably connected to another torque delivery elementor is anchored and held stationary with respect to a transmissionhousing. The terms “coupling”, “clutch” and “brake” may be usedinterchangeably.

A pocket plate may be provided with angularly disposed recesses orpockets about the axis of the one-way clutch. The pockets are formed inthe planar surface of the pocket plate. Each pocket receives a torquetransmitting strut, one end of which engages an anchor point in a pocketof the pocket plate. An opposite edge of the strut, which may hereafterbe referred to as an active edge, is movable from a position within thepocket to a position in which the active edge extends outwardly from theplanar surface of the pocket plate. The struts may be biased away fromthe pocket plate by individual springs.

A notch plate may be formed with a plurality of recesses or notcheslocated approximately on the radius of the pockets of the pocket plate.The notches are formed in the planar surface of the notch plate.

Another example of an overrunning planar clutch is disclosed in U.S.Pat. No. 5,597,057.

Some U.S. patents related to the present invention include: U.S. Pat.Nos. 4,056,747; 5,052,534; 5,070,978; 5,449,057; 5,486,758; 5,678,668;5,806,643; 5,871,071; 5,918,715; 5,964,331; 5,979,627; 6,065,576;6,116,394; 6,125,980; 6,129,190; 6,186,299; 6,193,038; 6,386,349;6,481,551; 6,505,721; 6,571,926; 6,814,201; 7,153,228; 7,275,628;8,051,959; 8,196,724; and 8,286,772.

Yet still other related U.S. patents include: U.S. Pat. Nos. 4,200,002;5,954,174; and 7,025,188.

U.S. Pat. No. 6,854,577 discloses a sound-dampened, one-way clutchincluding a plastic/steel pair of struts to dampen engagement clunk. Theplastic strut is slightly longer than the steel strut. This pattern canbe doubled to dual engaging. This approach has had some success.However, the dampening function stopped when the plastic parts becameexposed to hot oil over a period of time.

Metal injection molding (MIM) is a metalworking process wherefinely-powdered metal is mixed with a measured amount of binder materialto comprise a ‘feedstock’ capable of being handled by plastic processingequipment through a process known as injection mold forming. The moldingprocess allows complex parts to be shaped in a single operation and inhigh volume. End products are commonly component items used in variousindustries and applications. The nature of MIM feedstock flow is definedby a science called rheology. Current equipment capability requiresprocessing to stay limited to products that can be molded using typicalvolumes of 100 grams or less per “shot” into the mold. Rheology doesallow this “shot” to be distributed into multiple cavities, thusbecoming cost-effective for small, intricate, high-volume products whichwould otherwise be quite expensive to produce by alternate or classicmethods. The variety of metals capable of implementation within MIMfeedstock are referred to as powder metallurgy, and these contain thesame alloying constituents found in industry standards for common andexotic metal applications. Subsequent conditioning operations areperformed on the molded shape, where the binder material is removed andthe metal particles are coalesced into the desired state for the metalalloy.

Other U.S. patent documents related to at least one aspect of thepresent invention includes U.S. Pat. Nos. 9,255,614; 9,234,552;9,127,724; 9,109,636; 8,888,637; 8,813,929; 8,491,440; 8,491,439;8,286,772; 8,272,488; 8,187,141; 8,079,453; 8,007,396; 7,942,781;7,690,492; 7,661,518; 7,455,157; 7,455,156; 7,451,862; 7,448,481;7,383,930; 7,223,198; 7,100,756; and 6,290,044; and U.S. publishedapplication Nos. 2015/0061798; 2015/0000442; 2014/0305761; 2013/0277164;2013/0062151; 2012/0152683; 2012/0149518; 2012/0152687; 2012/0145505;2011/0233026; 2010/0105515; 2010/0230226; 2009/0233755; 2009/0062058;2009/0211863; 2008/0110715; 2008/0188338; 2008/0185253; 2006/0124425;2006/0249345; 2006/0185957; 2006/0021838, 2004/0216975; and2005/0279602.

Some other U.S. patent documents related to at least one aspect of thepresent invention includes U.S. Pat. Nos. 8,720,659; 8,418,825;5,996,758; 4,050,560; 8,061,496; 8,196,724; and U.S. publishedapplication Nos. 2014/0190785; 2014/0102844; 2014/0284167; 2012/0021862;2012/0228076; 2004/0159517; and 2010/0127693.

As used herein, the term “sensor” is used to describe a circuit orassembly that includes a sensing element and other components. Inparticular, as used herein, the term “magnetic field sensor” is used todescribe a circuit or assembly that includes a magnetic field sensingelement and electronics coupled to the magnetic field sensing element.

As used herein, the term “magnetic field sensing element” is used todescribe a variety of electronic elements that can sense a magneticfield. The magnetic field sensing elements can be, but are not limitedto, Hall effect elements, magnetoresistance elements, ormagnetotransistors. As is known, there are different types of Halleffect elements, for example, a planar Hall element, a vertical Hallelement, and a circular vertical Hall (CVH) element. As is also known,there are different types of magnetoresistance elements, for example, agiant magnetoresistance (GMC) element, an anisotropic magnetoresistanceelement (AMR), a tunneling magnetoresistance (TMR) element, an Indiumantimonide (InSb) sensor, and a magnetic tunnel junction (MTJ).

As is known, some of the above-described magnetic field sensing elementstend to have an axis of maximum sensitivity parallel to a substrate thatsupports the magnetic field sensing element, and others of theabove-described magnetic field sensing elements tend to have an axis ofmaximum sensitivity perpendicular to a substrate that supports themagnetic field sensing element. In particular, planar Hall elements tendto have axes of sensitivity perpendicular to a substrate, whilemagnetoresistance elements and vertical Hall elements (includingcircular vertical Hall (CVH) sensing element) tend to have axes ofsensitivity parallel to a substrate.

Magnetic field sensors are used in a variety of applications, including,but not limited to, an angle sensor that senses an angle of a directionof a magnetic field, a current sensor that senses a magnetic fieldgenerated by a current carried by a current-carrying conductor, amagnetic switch that senses the proximity of a ferromagnetic object, arotation detector that senses passing ferromagnetic articles, forexample, magnetic domains of a ring magnet, and a magnetic field sensorthat senses a magnetic field density of a magnetic field.

SUMMARY

An object of at least one embodiment of the present invention is toprovide a low cost controllable coupling assembly and a coupling memberfor use in the assembly.

In carrying out the above object and other objects of at least oneembodiment of the present invention, a coupling member for use in acontrollable coupling assembly is provided. The member includes a firstcoupling face oriented to face axially along a rotational axis andhaving a set of locking formations. Each of the set of lockingformations defining a first load-bearing surface adapted for abuttingengagement with a load-bearing surface of a first locking element. Themember also includes a second coupling face oriented to face radiallywith respect to the axis. The second coupling face has a reverse pocketreceiving a reverse locking element and defines a second load-bearingsurface adapted for abutting engagement with a load-bearing surface ofthe reverse locking element.

The set of locking formations may be spaced-apart forward cams.

The set of locking formations may be forward locking formations.

The reverse locking element may be a radial pawl.

The coupling member may be an outer coupling member.

The assembly may further include a biasing member to bias the reverselocking element. The biasing member may bias the reverse locking elementtowards an uncoupling position.

Further in carrying out the above object and other objects of at leastone embodiment of the present invention, a controllable couplingassembly having multiple operating modes is provided. The assemblyincludes first and second coupling members supported for rotationrelative to one another about a common rotational axis in a firstoperating mode. The first coupling member includes a first coupling faceoriented to face axially along the axis and having a set of lockingformations. Each of the set of locking formations defines a firstload-bearing surface adapted for abutting engagement with a load-bearingsurface of a first locking element in a second operating mode. The firstcoupling member also includes a second coupling face oriented to faceradially with respect to the axis. The second coupling face has areverse pocket receiving a reverse locking element and defining a secondload-bearing surface adapted for abutting engagement with a load-bearingsurface of the reverse locking element in a third operating mode.

The second coupling member may be a plate and has a set of forwardpockets angularly spaced about the axis and a set of spaced-apartreverse cams.

The reverse cams may be greater in number than the forward pockets.

The spaced-apart reverse cams may be spaced-apart locking teeth.

The plate has a width wherein each reverse cam may extend the entirewidth of the plate.

The second coupling member may be a splined ring having an outercircumferential surface formed with a set of locking formations.

The set of forward pockets may receive forward locking elements and theset of locking formations may be forward locking formations.

Still further in carrying out the above object and other objects of atleast one embodiment of the present invention, a controllable couplingassembly for use in an electronic vehicular transmission is provided.The assembly includes first and second coupling members supported forrelative rotation about a rotational axis. The first coupling member hasa first coupling face oriented to face radially with respect to theaxis. The second coupling member having a second coupling face orientedto face radially with respect to the axis and having a set of lockingformations. Each of the locking formations defines a load-bearing secondsurface. The first coupling face is in close-spaced opposition to thesecond coupling face and has a reverse pocket defining a load-bearingfirst surface. A reverse locking element is received within the reversepocket in an uncoupling position and is movable outwardly from thereverse pocket to a coupling position to couple the first and secondcoupling members together. The coupling position is characterized byabutting engagement of the reverse locking element with the load-bearingfirst and second surfaces. The assembly also includes anelectromechanical component supported by the first coupling member. Thecomponent includes a housing part having a closed axial end, anelectromagnetic source including at least one excitation coil at leastpartially surrounded by the housing part and a reciprocating memberarranged concentrically relative to the at least one excitation coil.The reciprocating member is axially movable to move the reverse lockingelement to either the coupling position or the uncoupling position whenthe at least one excitation coil is supplied with current.

The reverse locking element may include at least one projecting legportion. Each leg portion has an aperture. The assembly may furtherinclude a pivot pin received within each aperture to allow rotationalmovement of the locking element in response to reciprocating movement ofthe reciprocating member.

A leading end of the reciprocating member may be connected to thereverse locking element via the pivot pin.

The reverse locking element may be spring-loaded.

The housing part may have at least one attachment flange to attach thecomponent to the first coupling member.

The locking formations may comprise radially extending, angularly-spacedteeth.

The component may comprise a solenoid.

The second coupling member has a width wherein each locking formationmay extend the entire width of the second coupling member.

The assembly may further comprise a biasing member to bias thereciprocating member to an extended position.

The reciprocating member and the reverse locking element may beconnected together.

While exemplary embodiments are described above, it is not intended thatthese embodiments describe all possible forms of the invention. Rather,the words used in the specification are words of description rather thanlimitation, and it is understood that various changes may be madewithout departing from the spirit and scope of the invention.Additionally, the features of various implementing embodiments may becombined to form further embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a controllable coupling assembly and anelectromechanical component constructed in accordance with at least oneembodiment of the parent application to this application;

FIG. 2 is an exploded, perspective view of the assembly and component ofFIG. 1;

FIG. 3 is a view of the assembly and component similar to the view ofFIG. 2 but from a different angle;

FIG. 4 is an enlarged side view, partially broken away, of the assemblyand component of FIG. 1 together with a second electromechanicalcomponent in phantom with locking elements of the components partiallyextended towards locking formations of a coupling member of theassembly;

FIG. 5 is a partial block diagram and side view, opposite the side viewof FIG. 4, but with one of the components in cross section and insertedin a case (also in cross section) of an electronic vehicle transmissionconstructed in accordance with at least one embodiment of the parentapplication to this application;

FIG. 6 is a perspective, schematic bottom view of the electromechanicalcomponent of the prior Figures;

FIG. 7 is an exploded, perspective view of the electromechanicalcomponent;

FIG. 8 is a schematic perspective front view, partially broken away, ofa controllable coupling assembly and an electromechanical componentconstructed in accordance with at least one embodiment of the presentinvention;

FIG. 9 is a view, similar to the view of FIG. 8, but showing the rear ofthe assembly and the component;

FIG. 10 is a side schematic view, partially broken away, of thecomponent attached to a raised portion of an outer coupling member ofthe assembly via a bracket;

FIG. 11 is a view, similar to the view of FIG. 9, but showing the top ofthe assembly, the component and the bracket;

FIG. 12 is a view, similar to the FIG. 11, but without the bracket;

FIG. 13 is a schematic perspective top view of the bracket of FIG. 11;

FIG. 14 is a schematic perspective bottom view of the bracket of FIG.13;

FIG. 15 is a schematic perspective view, partially broken away, of therear of the outer coupling member with a supported component;

FIG. 16 is a top, schematic perspective view, partially broken away, ofthe coupling member of FIG. 15 without the component;

FIG. 17 is a side elevational view, partially broken away, of thecoupling member of FIGS. 15 and 16;

FIG. 18 is a side, schematic perspective view, partially broken away, ofthe coupling member of FIGS. 15-17;

FIG. 19 is a schematic perspective top view of another embodiment of theelectromechanical component with a printed current board with electricalcomponents supported on a top surface of the component;

FIG. 20 is a side view, partially broken away and in cross section, ofthe component attached to the raised portion of the outer couplingmember and with a radial pawl shown in its uncoupling or retractedposition;

FIG. 21 is an enlarged side view, partially broken away and in crosssection and similar to the view of FIG. 20, but further including avented, spring-loaded plunger on the heel of a pawl which is in itsextended, coupling position;

FIG. 22 is a schematic perspective bottom view, partially broken awayand in cross section and similar to the view of FIG. 21, but alsoshowing a speed sensor;

FIG. 23 is a side view, partially broken away and in cross section andsimilar to the views of FIGS. 21 and 22, with the pawl in its retractedposition and further illustrating the inner coupling member;

FIG. 24 is an enlarged side view, partially broken away and in crosssection, showing a spring-loaded radial pawl pushed by a plunger orreciprocating member of the electromechanical component into itscoupling position in which the pawl abuttingly engages a tooth on theinner coupling member;

FIG. 25 is a view, similar to the view of FIG. 24, but with the plungerin its retracted position and the pawl in its “off” or uncouplingposition; and

FIG. 26 is a view similar to the views of FIGS. 24 and 25 but with thepawl attached or connected to a free or distal end of the reciprocatingmember or plunger via a clevis-type connection (not dissimilar to theconnection of FIG. 7); the coupling position of the pawl is shown byphantom lines.

DETAILED DESCRIPTION

As required, detailed embodiments of the present invention are disclosedherein; however, it is to be understood that the disclosed embodimentsare merely exemplary of the invention that may be embodied in variousand alternative forms. The figures are not necessarily to scale; somefeatures may be exaggerated or minimized to show details of particularcomponents. Therefore, specific structural and functional detailsdisclosed herein are not to be interpreted as limiting, but merely as arepresentative basis for teaching one skilled in the art to variouslyemploy the present invention.

Referring now to the drawing figures, there is illustrated oneembodiment of an electronic vehicular transmission, generally indicatedat 10 in FIG. 5. The transmission 10 includes a transmission case 40having a bore 41 which extends completely through the case 40. As iswell known in the art, the transmission case 40 has associated therewithan environment which is hostile to electrical components during use ofthe transmission 10 primarily because of: (1) hot oil contained therein,(2) contaminants in the oil which cause shorting of any electricalcircuits therein and (3) vibration.

The transmission 10 also includes an electromechanical component,generally indicated at 14, which is capable of operating in the hostileenvironment of the case 40. The component 14 may be referred to hereinbelow as an SSI (i.e. selectable solenoid insert). The component 14 isinserted through the bore 41 and held therein by threaded fasteners (notshown) which extend through holes 46 formed through an annular flange 44of a housing, generally indicated at 48, of the component 14. Thefasteners extend into threshold holes 42 formed in the case 40 about thebore 41 to secure the component 14 to the case 40.

Referring now to FIGS. 1-3, the transmission 10 also includes acontrollable coupling assembly, generally included at 12, which, inturn, includes first and second coupling members, 18 and 22,respectively, mounted for rotation relative to one another about arotational axis 16. The first coupling member 18 has a first couplingface 19 oriented to face axially in a first direction with respect tothe axis 16 and the second coupling member 22 has a second coupling face23 oriented to face axially in a second direction opposite the firstdirection with respect to the axis 16. The second coupling member 22also has a third coupling face 25 oriented to face radially with respectto the axis 16 and having a set of locking formations or teeth 30 formedtherein. The teeth 30 are preferably ferromagnetic or magnetic teeth 30.

The coupling assembly 12 also includes a set of forward locking elementsor struts 20 which are received within angularly spaced pockets 26formed in the face 23 of the coupling member 22. The coupling member 22has a set of splines 28 formed on its inner diameter for drivinglyengaging a drive or driven member (not shown) for rotation about theaxis 16.

The assembly 12 also includes a locking ring or plate, generallyindicated at 24, for insertion into an annular groove 36 of an axiallyextending wall 37 of the coupling member 18 to hold the coupling members18 and 22 together. The locking plate 24 has a circumferential cutout 34which coincides or is aligned with a circumferential cutout 32 providedin the wall 37 of the member 18 when the plate 24 is inserted into thegroove 36. This feature allows a locking element or strut 52 of thecomponent 14 to engage the teeth 30 of the member 22 as shown in FIGS. 4and 5.

The housing part or housing 48 has an outer coupling face 49 (FIG. 5) inclose-spaced opposition to the coupling face 25 of the member 22 whenthe members 18 and 22 are joined and assembled together by the lockingring 24 and after insertion of the component 14 into the bore 41 of thecase 40.

The outer coupling face 49 of the housing part 48 has a single, T-shapedrecess or pocket 51. The recess 51 defines a load-bearing first surfaceshoulder 53. The coupling face 25 of the member 22 has a plurality ofreverse notches or teeth 30. Each tooth of the teeth 30 defines aload-bearing second surface or shoulder 31.

The locking strut or element 52 is capable of extending between thecoupling faces 25 and 49 of the member 22 and the part 48, respectively,between coupling and uncoupling positions when the assembly 12 and case40 are assembled together as is shown in FIGS. 4 and 5.

The element 52 may comprise a ferromagnetic locking element or strutmovable between first and second positions. The first position (i.e.coupling position) is characterized by abutting engagement of thelocking element 52 with the load-bearing surface or shoulder 31 of oneof the teeth 30 and the shoulder 53 of the pocket 51 formed in an endwall of the housing part 48. The second position (i.e. non-couplingposition) is characterized by non-abutting engagement of the lockingelement 52 with a load-bearing shoulder 31 of at least one of the teeth30 and the end wall of the housing part 48.

The electromechanical component or apparatus (i.e. SSI) 14 includes thehousing part 48 which has a closed axial end including the end wall. Theend wall has the outer coupling face 49 with the single pocket 51 whichdefines the load-bearing shoulder 53 which is in communication with aninner face of the end wall. The housing part 48 may be a metal (such asaluminum) injection molded (MIM) part.

The apparatus 14 also includes an electromagnetic source, including atleast one excitation coil 62 which is at least partially surrounded by askirt of the housing part 48.

Electrical insulated wiring 64 supplies electrical power to the coil 62from a power source located outside the hot oil environment. The wiring64 extends from the coil 62, through a hole 65 (FIG. 5) formed throughan end seal 82, through a cavity 86 formed through an overmold 84 and toa solenoid controller.

The strut 52 is retained within the pocket 51 by a clevis-shapedretainer 50. The strut 52 is movable outwardly from the pocket 51 to itsextended, coupling position characterized by abutting engagement of thestrut 52 with a load-bearing surface or shoulder 31 of one of the teeth30.

The apparatus 14 also includes a reciprocating plunger, generallyindicated at 70, arranged concentrically relative to the at least oneexcitation coil 62 and is axially movable when the at least oneexcitation coil 62 is supplied with current via the wires 64. The coil62 is wound or located about an actuator core or armature 76 and ispotted between plates 60 and 78. The armature 76 is also axially movableupon coil excitation. The plate 60 abuts against the inner face of thehousing end wall. The plunger 70 extends through a hole 61 (FIG. 7)formed through the plate 60 and is connected at its leading end 72 tothe element 52 to move the element 52 between its coupling anduncoupling positions. The plunger 70 also extends through an aperture 75formed through the armature 76. The opposite end of the plunger 70 has alocking nut or cap 80 positioned thereon which limits movement of theplunger 70 in the aperture 75 towards the teeth 30 by abutting againstthe lower surface of an annular spacer 68 which abuts against the lowersurface of the armature 76.

The element 52 is pivotally connected to the apertured leading end 72 ofthe plunger 70 wherein the plunger 70 pivotally moves the element 52within the pocket 51 in response to reciprocating movement of theplunger 70 which, in turn, moves axially in response to reciprocatingmovement of the armature 76.

The apparatus 14 also preferably includes a return spring 66, whichextends between the plate 60 and a shoulder in the outer surface of theactuator core or armature 76, to return the plunger 70 and the armature76 to their home position when the coil 62 is de-energized, therebyreturning the element 52 to its uncoupling position. The apparatus 14also includes a spring 74 which urges the plunger 70 to move the element52 towards its coupling position. In other words, the biasing member orspring 66, urges the plunger 70 via the armature 76 to a return positionwhich corresponds to its uncoupling position of the element 52 while thebiasing member or spring 66 urges the plunger 70 and its connectedelement 52 to its coupled position.

The housing part 48 and/or the plate 78 may have holes (not shown) toallow oil to circulate within the housing part 48. Preferably, the atleast one coil 62, the housing part 48, the armature 76 and the plunger70 comprise a low profile solenoid. The locking element 52 may be ametal (such as aluminum) injection molded (i.e. MIM) strut.

The element 52 includes at least one and, preferably, two projecting legportions 55 which provide an attachment location for the leading end 72of the plunger 70. Each leg portion 55 has an aperture 57. The apparatus14 further comprises a pivot pin 54 received within each aperture 57 andthe aperture formed in the leading end 72 to allow rotational movementof the element 52 in response to reciprocating movement of the plunger70 wherein the leading end 72 of the plunger 70 is connected to theelement 52 via the pivot pin 54.

Preferably, each aperture 55 is an oblong aperture which receives thepivot pin 54 to allow both rotation and translational movement of theelement 52 in response to reciprocating movement of the plunger 70. Eachlocking strut 52 may comprise any suitable rigid material such asferrous metal, (i.e. steel).

The component 14 also includes a magnetic field speed sensor or device56 which may comprise a differential Hall-effect device which sensesspeed of the teeth 30 as they rotate past the sensor 56. The teeth 30may carry or support a rare-earth, automotive grade, magnet or pellet(not shown) which may be embedded in a hole formed in the outer surfaceof the teeth. In that case, the teeth 30 may be non-ferrous teeth suchas aluminum teeth. Alternatively, and preferably, the teeth 30 areferromagnetic teeth.

The device 56 is typically back-biased, has two wires 58 (FIG. 7) andprovides a current output based on speed of rotation of the teeth 30past the sensor 56. The device 56 accurately detects the speed with asingle output (i.e., current output). The device 56 is preferablymounted adjacent to the pocket 51 and the wires 58 extend through theaperture 61 formed in the plate 60. The wires 58 and the wires 64 of thecoil 62 are coupled to the solenoid controller which, in turn, iscoupled to a main controller to supply drive signals to the coil 62 inresponse to control signals from the main controller. The device 56 maybe held in place by fasteners or by an adhesive so that a side surfaceof the device 56 is in close proximity to a side surface of the strut 52in the uncoupling position of the strut 52.

The sensor 56 is typically back-biased when the teeth 30 areferromagnetic and typically includes a Hall sensor or sensing elementmounted on a circuit board on which other electronics or components aremounted, as is well-known in the art. The sensor 56 is preferablyback-biased in that it includes a rare-earth magnet which creates amagnetic flux or field which varies as the teeth 30 move past the sensor56. The sensor 56 may comprise a back-biased, differential Hall Effectdevice.

In other words, the device 56 is preferably a back-biased device whereinthe device 56 includes a rare earth pellet or magnet whose magneticfield varies as the teeth 30 move therepast. The variable magnetic fieldis sensed by the magnetic sensing element of the device 56.

The output signal from the device 56 is a feedback signal which isreceived by the solenoid controller. By providing feedback, theresulting closed-loop control system provides for true speed operation.

As described above, the number of forward struts (i.e. 14) is greaterthan the number of reverse struts (i.e. one or two). Also, the number ofreverse notches is greater than the number of forward notches. In thissituation, there is a possibility of a coupling assembly such as thecoupling assembly 12 to enter a “lock-lock” condition wherein thetransitional backlash (i.e., distance the clutch can move betweenforward and reverse directions) is extremely low. This results in thelocking elements not being allowed to drop out of their couplingpositions upon command.

In order to avoid the above-described problem, the number of reversestruts and notches and the number of forward struts and notches arechosen so that the forward backlash is a non-zero integer multiple (i.e.“N”) of the reverse backlash and the forward pockets are uniformlyangularly spaced about the axis 16. The following is a table of 36entries wherein only entries 11, 14 and 15 do not satisfy the abovecriteria.

Reverse Reverse Reverse Forward Forward Forward Transitional Entry NNotches Struts Backlash Notches Strut Sets Backlash Backlash 1 2 79 14.556962 79 2 2.278481 1.139241 2 2 77 1 4.675325 77 2 2.337662 1.1688313 3 80 1 4.5 80 3 1.5 0.75 4 3 79 1 4.556962 79 3 1.518987 0.759494 5 377 1 4.675325 77 3 1.558442 0.779221 6 3 76 1 4.736842 76 3 1.5789470.789474 7 3 74 1 4.864865 74 3 1.621622 0.810811 8 3 73 1 4.931507 73 31.643836 0.821918 9 3 71 1 5.070423 71 3 1.690141 0.84507 10 3 70 15.142857 70 3 1.714286 0.857143 11 3 62 1 5.806452 62 3 1.9354840.967742 12 3 61 1 5.901639 61 3 1.967213 0.983607 13 3 59 1 6.101695 593 2.033898 1.016949 14 3 58 1 6.206897 58 3 2.068966 1.034483 15 3 56 16.428571 56 3 2.142857 1.071429 16 3 55 1 6.545455 55 3 2.1818181.090909 17 3 53 1 6.792453 53 3 2.264151 1.132075 18 3 52 1 6.923077 523 2.307692 1.153846 19 1 79 2 2.278481 79 2 2.278481 1.139241 20 1 77 22.337662 77 2 2.337662 1.168831 21 1 79 3 1.518987 79 3 1.5189870.759494 22 1 80 3 1.5 80 3 1.5 0.75 23 1 79 3 1.518987 79 3 1.5189870.759494 24 1 77 3 1.558442 77 3 1.558442 0.779221 25 1 76 3 1.578947 763 1.578947 0.789474 26 1 74 3 1.621622 74 3 1.621622 0.810811 27 1 73 31.643836 73 3 1.643836 0.821918 28 1 71 3 1.690141 71 3 1.690141 0.8450729 1 70 3 1.714286 70 3 1.714286 0.857143 30 1 61 3 1.967213 61 31.967213 0.983607 31 1 59 3 2.033898 59 3 2.033898 1.016949 32 1 58 32.068966 58 3 2.068966 1.034483 33 1 56 3 2.142857 56 3 2.1428571.071429 34 1 55 3 2.181818 55 3 2.181818 1.090909 35 1 53 3 2.264151 533 2.264151 1.132075 36 1 52 3 2.307692 52 3 2.307692 1.153846

General Advantages

Wiring is outside the transmission.

Eliminates the difficulty in routing lead wires from the clutch aroundrotating parts to the bulk head inside the box.

Does not impact the number of wires passing through the bulk headconnector.

Coils are potted, leads are over molded, connector is external,completely segregated from the hot oil environment which prevents:

Long term embrittlement of connector and wire insulation from hot oilexposure;

Eliminates the possibility of contamination in oil shorting the circuitto power; and

Vibration failures are greatly reduced (potted and over molded).

High Power Density—every surface of the inner and outer race is used.The radial surfaces are for reverse and the planar surfaces are for 1stgear. They are independent and do not compete for the same real estatein the races. The concentric design competes for radial cross sectionand co-planar designs add a PM race. The largest possible strut/camgeometry can be used in a smaller package. This increases the powerdensity of the clutch.

Using the SSI 14 as a common electro-mechanical component.

Tend to make it a high volume commodity thus reducing cost.

Streamlines design, validation, and manufacturing—one and done approach.

Better resource allocation. Engineering can focus on clutch designwithout the burden of designing a new electro-mechanical solution foreach unique application.

Eliminate the slide plate and failure modes associated with the slideplate.

Traditional MD approach—no concentric, co-planar design. Tried and trueapproach.

Cost competitive—highest power density, 2 races, and an across the boardapproach for controls using the SSIs 14.

Reduction of partial engagements.

The SSI 14 strut 52 turns on faster than a hydraulic design using aslide plate.

The SSI 14 can be turned on closer to the sync point when doing arolling forward reverse shift because it takes only 20 ms or less tofire on. No hydraulic delay or temperature effects.

Soft Turn Off Capable Reduces Impact Loads when Turning Off

No special driver is required. The SSI 14 can fire initially and can bePWMed down to hold on. The higher pulse is to overcome a return springdesigned for a 20 g impact.

NVH Advantages—Maximizing cams is great approach to reducing backlash.Many more cams can be formed into the race in the radial direction asopposed to the planar direction. Using the SSI 14 in the radialdirection takes advantage of this feature.

Usually there is one outer race where the forward and reverse flanks ofa spline are the path to ground. This design splits the paths. There isno backlash in the reverse direction as the path passes through a pressfit SSI 14 into the case 40. The SSI 14 only reacts reverse torque. Theouter race for the passive clutch conversely only sees forward reactiontorque. The result is a system where the clutch does not travel throughan external lash. The drive side spline stays on the drive side and thereverse drive path is in a press fit SSI 14. This reduces tick/clunk inthe splines. A rubber washer/spring clip can be added to the coast sideof the spline to keep the spline engaged with the case at all times. Itnever experiences reverse torque.

Advantages Over Hydraulic

Temperature insensitive.

Faster reaction time with small tolerance (20 ms or less).

Much less energy to operate over life of application.

Easier to route wires outside of box compared to packaging worm trails.

Easy for diagnostic—software maintenance loop with a trickle voltage canmeasure resistance for temperature, continuity, or a short instantlysetting a code.

Contamination Insensitive

Advantages of Two Springs

If the armature 76 was directly connected to the strut 52 with a singlereturn spring, a constant high current would have to be applied toensure the device turns ON. The lowest stroking force occurs initiallyat the highest gap when the armature 76 is in the OFF position. If thearmature 76 was directly attached to the strut 52 and the strut 52 wasin between notches or teeth 30, a high current would have to be held toensure the device would always stroke to ON eventually. The cam plate 22would have to rotate so the strut 52 could drop in. So a consistentlyhigh current would have to be maintained as long as the solenoid 14 wasON. This is a problem. The solenoid 14 could overheat using thisapproach. The solution is to use two springs 66 and 76, an actuator coreor armature 76, and a second internal piston called the plunger 70 thatattaches to the strut 52 via a clevis connection. In this arrangement,the armature 76 always strokes ON and travels the full 3 mm closing thegap independent of the position of the strut 52 relative to the cams orteeth 30. The forces keeping the armature 76 in the ON position increaseby a magnitude when the gap is closed. The armature 76 pushes the secondspring 74 that pushes the plunger 70 attached to the strut 52.

Once the armature 76 strokes the 3 mm, the current can be dropped to aholding current that is a fraction of the initial pulse current. Thestrut 52 is loaded by the second spring 74 in the apply direction. Ifthe strut 52 is in between cams or teeth 30, there is a second springforce pushing the strut 52 into the ON position as soon as the cam plate22 rotates. The armature 70 is now independent of strut position and canbe PWMed.

If one used a single spring in a tooth butt condition, the armature 76would only stroke 1.3 mm and stop with a force of about 2 lbs. In atwo-spring system the armature 76 always strokes the full 3 mm in 20 msallowing the current to drop to a holding current. The second spring 74applies the force to exit tooth butt.

Advantages of Speed Sensor with the Component (i.e. SSI)

The prior art has a speed sensor that passes through the outside of theouter race of the clutch to sense the speed of the inner race. It waspresumed that it is for the non-sync reverse shift when rolling in theforward direction.

At least one embodiment of the present invention provides the structurefor a speed sensor chip set. It is possible to pot in a speed sensorchip set right into the SSI 14. This has the advantage of flexing thestructure of the SSI 14 to not only lock the inner race to ground inreverse, but also to sense the inner race speed all in the same part.This would eliminate the stand alone speed sensor, case machining andclutch machining to accommodate the stand alone speed sensor. This is asignificant cost save.

Referring now to FIGS. 8-26, there is illustrated an embodiment of thepresent invention wherein parts which are the same or similar to theparts of FIGS. 1-7 in either structure and/or function have the samereference number added to the number “100”.

Also, parts of a second or third embodiment have the same referencenumber but a single or double prime designation, respectively.

A coupling and control assembly, generally indicated at 112, includes aspeed sensor 156 (FIGS. 22-26) for providing an electrical signal forelectronic transmission control. The sensor 156 is generally of the sametype as the sensor 56 of FIGS. 1-7.

The assembly 112 includes a controllable coupling assembly, having firstand second coupling members 118 and 122, respectively, supported forrotation relative to one another about a rotational axis 116. Theelectrical signal from the speed sensor 156 is based on the relativerotary speed of the second coupling member 122.

The first coupling member 118 has a first coupling face 149 (FIGS. 17and 18) oriented to face radially with respect to the axis 116 and has alocking element 152 (FIGS. 20-23, 152′ in FIGS. 24 and 25 and 152″ inFIG. 26) disposed within a pocket or recess 151 (or 151′ or 151″,respectively). The recess 151 defines a load bearing first surfaceshoulder 153 or 153′ or 153″. The sensor 156 is also disposed within therecess 151 (or 151′ or 151″). The first coupling member 118 also has acoupling face 119 oriented to face axially with respect to the axis 116.The coupling face 119 (FIG. 22) has a set of axially spaced, lockingformations 129 formed therein (FIGS. 17 and 18).

The second coupling member 122 has a set of splines 128 formed on itsinner diameter (FIGS. 8, 9 and 23), a second coupling face 125 orientedto face radially with respect to the axis 116 and a set of ferromagneticor magnetic locking formations or teeth 130 on its outer diameter. Eachtooth 130 defines a load-bearing surface shoulder 131. The secondcoupling member 122 also has an axially facing coupling face 123 with aset of angularly spaced forward pockets 126 (one of which is shown inFIG. 22) for receiving and retaining a set of angularly spaced forwardpawls (not shown but similar to the pockets 26 and the struts 20 in FIG.2).

The first and second members 118 and 122, respectively, are positionedrelative to each other so that the locking element 152 (or the lockingelements 152′ and 152″) and the sensor 156 are in close-spacedopposition to the locking formations 130.

The assembly 112 also includes a locking ring or plate 124 for insertioninto an annular groove 136 formed in an axially extending wall 137 ofthe coupling member 118 to hold the coupling members 118 and 122together.

The first coupling member 118 includes a cutout or hole 132 whichextends into a raised portion 135 of the member 118. A slit 127 extendscompletely through the member 118 from the hole 132 to the face 149.

The assembly 112 also includes a locking ring or plate 124 for insertioninto an annular groove 136 formed in an axially extending wall 137 ofthe coupling member 118 to hold the coupling members 118 and 122together.

The first coupling member 118 includes a cutout or hole 132 whichextends into a raised portion 135 of the member 118. A slit 127 extendscompletely through the member 118 or from the hole 132 to the face 149.

The assembly 112 also includes an electromechanical component, generallyindicated at 114 and 114′ (FIG. 19), and includes a reciprocating member170 (or 170′ in FIG. 19). The component 114 is supported in the hole 132so that the reciprocating member 170 reciprocates in the slit 127 andmoves the locking element 152 across a gap between the coupling faces149 and 125 in response to the component 114 receiving an electricalcontrol signal. The locking element 152 abuttingly engage one of thelocking formations 130 in a coupling position of the locking element 152(i.e. FIGS. 21 and 24) to prevent relative rotation in one directionabout the axis 116. The component 114 has a housing 148 which is held inthe hole 132 by a u-shaped bracket 129 having legs 133 and a resilientgripping portion 135 which grip beveled portions 138 of the raisedportion 135.

The component 114′ is preferably generally of the type disclosed inpublished U.S. patent application No. 2015/0061798. As describedtherein, the component 114′ is an electromagnetic solenoid 114′including a housing 148′ and having a bottom part 160′ with an aperture161′ in which the member 170′ reciprocates at a first end and a magneticcoil 162′ supported within the housing 148′ An armature 176′ issupported for axial movement within the housing 148′ between first andsecond positions when the coil 162′ is energized with a predeterminedelectrical current. The distance between the first and second positionsdefines a stroke length wherein the armature 176′ exerts a substantiallyconstant force along its stroke length during axial movement of thearmature 176′ between the first and second positions. A pin or thereciprocating member 170′ is biased by a spring 174′ which extendsbetween the member 170′ and the armature 176′ to move axially betweenfirst and second positions. The spring 174′ biases the member 170′towards the second coupling member 122.

The sensor 156 senses magnetic flux to produce an electrical outputsignal indicative of a speed of the relative rotation of the secondcoupling member 122. A variable magnetic field is generated in responseto rotation of the locking formations 130 past the sensor 156.

The sensor 156 preferably includes a magnetic field sensing element. Thesensor 156 may be back-biased wherein the locking formations 130 areferromagnetic. The sensor 156 has wires 158 which together with thewires (not shown) of the coil 162 extend through a cavity 186 of anovermold 184 and are coupled to a solenoid controller.

The locking formations 130 may comprise radially extending,angularly-spaced teeth 130.

The locking element 152 or 152′ or 152″ is preferably a radial pawl.

As best shown in FIG. 22, the second coupling member 122 has a widthwherein each locking formation 130 extends the entire width of thesecond coupling member 122.

The first coupling member 118 preferably is an outer coupling member andthe second coupling member 122 is preferably an inner coupling member.

The assembly 112 may further comprise a spring or biasing member 166 or166′ to bias the locking member 152 or 152′ or 152″, respectively,towards an uncoupling position as shown in FIGS. 22, 23 and 25. Thebiasing member 166 biases a vented pin 167 to engage the heel of thelocking member 152 and bias the member 152 towards its uncouplingposition. The pin 167 is vented to permit lubricating oil to flowtherethrough.

The biasing member 174′ biases the reciprocating member 170′ to itsextended position as shown in FIGS. 21 and 24.

A reciprocating member 170″ and a locking element 152″ of a differentembodiment may be connected together as shown in FIG. 26 via aclevis-type connection. The connection is defined by a pair of spacedleg portions 155″ integrally formed at a bottom surface of the element152″ which provide an attachment location for a leading or distal end172″ of the reciprocating member 170″. As in the embodiment of FIGS.1-7, each leg portion 155″ has an aperture 157″. A pivot pin 154″ isreceived within each aperture 157″ and an aperture formed in the leadingend 172″ to allow rotational movement of the element 152″ in response toreciprocating movement of the reciprocating member 170″.

While exemplary embodiments are described above, it is not intended thatthese embodiments describe all possible forms of the invention. Rather,the words used in the specification are words of description rather thanlimitation, and it is understood that various changes may be madewithout departing from the spirit and scope of the invention.Additionally, the features of various implementing embodiments may becombined to form further embodiments of the invention.

What is claimed is:
 1. A coupling member for use in a controllablecoupling assembly, the member comprising: a first coupling face orientedto face axially along a rotational axis and having a set of lockingformations, each of the set of locking formations defining a firstload-bearing surface adapted for abutting engagement with a load-bearingsurface of a first locking element; and a second coupling face orientedto face radially with respect to the axis and having a reverse pocketreceiving a reverse locking element and defining a second load-bearingsurface adapted for abutting engagement with a load-bearing surface ofthe reverse locking element.
 2. The coupling member as claimed in claim1, wherein the set of locking formations are spaced-apart forward cams.3. The coupling member as claimed in claim 1, wherein the set of lockingformations are forward locking formations.
 4. The assembly as claimed inclaim 1, wherein the reverse locking element is a radial pawl.
 5. Theassembly as claimed in claim 1, wherein the coupling member is an outercoupling member.
 6. The assembly as claimed in claim 1, furthercomprising a biasing member to bias the reverse locking element.
 7. Theassembly as claimed in claim 6, wherein the biasing member biases thereverse locking element towards an uncoupling position.
 8. Acontrollable coupling assembly having multiple operating modes, theassembly comprising: first and second coupling members supported forrotation relative to one another about a common rotational axis in afirst operating mode, the first coupling member including: a firstcoupling face oriented to face axially along the axis and having a setof locking formations, each of the set of locking formations defining afirst load-bearing surface adapted for abutting engagement with aload-bearing surface of a first locking element in a second operatingmode; and a second coupling face oriented to face radially with respectto the axis and having a reverse pocket receiving a reverse lockingelement and defining a second load-bearing surface adapted for abuttingengagement with a load-bearing surface of the reverse locking element ina third operating mode.
 9. The assembly as claimed in claim 8, whereinthe second coupling member is a plate and has a set of forward pocketsangularly spaced about the axis and a set of spaced-apart reverse cams.10. The assembly as claimed in claim 9, wherein the reverse cams aregreater in number than the forward pockets.
 11. The assembly as claimedin claim 9, wherein the spaced-apart reverse cams are spaced-apartlocking teeth.
 12. The assembly as claimed in claim 9, wherein the platehas a width and wherein each reverse cam extends the entire width of theplate.
 13. The assembly as claimed in claim 8, wherein the secondcoupling member is a splined ring having an outer circumferentialsurface formed with a set of locking formations.
 14. The assembly asclaimed in claim 9, wherein the set of forward pockets receive forwardlocking elements and the set of locking formations are forward lockingformations.
 15. A controllable coupling assembly for use in anelectronic vehicular transmission, the assembly comprising: first andsecond coupling members supported for relative rotation about arotational axis, the first coupling member having a first coupling faceoriented to face radially with respect to the axis and the secondcoupling member having a second coupling face oriented to face radiallywith respect to the axis and having a set of locking formations, each ofthe locking formations defining a load-bearing second surface, the firstcoupling face being in close-spaced opposition to the second couplingface and having a reverse pocket defining a load-bearing first surface,a reverse locking element received within the reverse pocket in anuncoupling position and movable outwardly from the reverse pocket to acoupling position to couple the first and second coupling memberstogether, the coupling position being characterized by abuttingengagement of the reverse locking element with the load-bearing firstand second surfaces; and an electromechanical component supported by thefirst coupling member and including: a housing part having a closedaxial end; an electromagnetic source including at least one excitationcoil at least partially surrounded by the housing part; and areciprocating member arranged concentrically relative to the at leastone excitation coil and being axially movable to move the reverselocking element to either the coupling position or the uncouplingposition when the at least one excitation coil is supplied with current.16. The assembly as claimed in claim 15, wherein the reverse lockingelement is spring-loaded.
 17. The assembly as claimed in claim 15,wherein the housing part has at least one attachment flange to attachthe component to the first coupling member.
 18. The assembly as claimedin claim 15, wherein the locking formations comprise radially extending,angularly-spaced teeth.
 19. The assembly as claimed 15, wherein thecomponent comprises a solenoid.
 20. The assembly as claimed in claim 15,wherein the second coupling member has a width and wherein each lockingformation extends the entire width of the second coupling member. 21.The assembly as claimed in claim 15, further comprising a biasing memberto bias the reciprocating member to an extended position.
 22. Theassembly as claimed in claim 15, wherein the reciprocating member andthe reverse locking element are connected together.